Rectangular conductor harness means and attachments



May 1967 D. cs. BAER ETAL RECTANGULAR CONDUCTOR HARNESS MEANS AND ATTACHMENTS Original Filed Sept. 28, 1961 Fig.4

Their Afl'orney United States Patent 3,322,882 RECTANGULAR CONDUCTOR HARNESS MEANS AND ATTACHMENTS Donald G. Baer, Girard, Allan S. Van Slyke, Southington, and Robert C. Woofter, Cortland, Ohio, assignors to General Motors Corporation, Detroit, Mich., a corporation of Delaware Original application Sept. 28, 1961, Ser. No. 141,483, now Patent No. 3,226,668, dated Dec. 28, 1965. Divided and this application Mar. 15, 1965, Ser. No. 439,847

4 Claims. (Cl. 174-72) This is a division of copending application Ser. No. 141,483, Baer et al., filed Sept. 28, 1961, now Patent 3,226,668, granted Dec. 28, 1965, and belonging to the assignee of the present invention.

This invention relates to wiring and electrical connec tions and, more particularly, to a rectangular conductor harness means and attachments for vehicle use. 7 An object of this invention is to provide a new and improved approach to automotive wiring to save space and reduce number and thickness of attachments and components including switches and terminal means for use therewith representing a transition from rounded condoctors in vehicle wiring harness means to flattened generally rectangular-shaped conductors more eflicient to use.

Another object of this invention is to provide rectangular-shaped conductors in parallel though separably insulated association as a unitary solid flat configuration with predetermined surfacing exposable by stripping as well as window-like cutouts to gain proper electrical connection thereto directly free of any intermediate terminal means in predetermined locations of the insulated flat conductors which can also have'single terminal contact anchoring holes, dimples as well as tang-like pierced deformations integral therewith adjacent to ends thereof.

A further object of this invention isto provide a flattended clamp-like retainer clip means of insulating material for use on flattened generally rectangular-shaped insulated conductors forming wiring harness means to be carried adjacent to a vehicle mounting panel and including formation of a hole longitudinally through flat rectangular cable. or wiring harness means to receive a lateral projection from a flat body portion of the clip means, the lateral projection being alternately heat fusible to in sulation of the wiring harness means as well as engageable by a separable clip retainer portion also of flattened insulating material.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein preferred embodiments of the present invention are clearly shown.

In the drawings:

FIGURE 1 illustrates in perspective a male pin terminal means adapted to fit a rectangular cable for example on a radio speaker connection as Well as a rectangular harness means provided with a flattened clamplike retainer clip means of insulating material heat fused to the insulation of the harness means having a hole therein.

FIGURE 2 is a cross-sectional view of an alternate clamp-like clip means for use with the harness means of FIGURE 1.

FIGURES 3 and 4 are plan views of clip portions attached to the flat harness means as illustrated in FIG- URE 2.

FIGURE 5 is an end view of the clip portion of FIG- URE 3.

Motor vehicle manufactures have produced bodies equipped with wiring means utilizing rounded conductors which can be grouped as a harness provided with a tape-v 3,322,882. Patented May 30, 1967 like covering and the like. Such rounded conductors as grouped into a harness can effect transfer of electric power to various electrical devices and switching means to which the wiring harness and conductor means can be routed generally in concealed positions between inner and outer panels of doors as well as between supports such as door jambs and vehicle upholstery and metal body panels including fenders and the like. There is a continuing trend in body construction in modification of vehicle bodies to increase strength thereof while reducing thickness or spacing between components. Future vehicles will also be provided with thinner door means that provide less space between inner and outer panels thus requiring new types of switch means and accessory devices due to limited space from a point of view of thickness between such mounting panels. In some instances a transition will be made by provision of both rounded as well as flattened insulated conductors and wiring means between which electrical interconnection must be established so that flattened conductor means or substantially rectangular-shaped insulated wiring harness means can be used where space accommodations are narrower and cannot permit placement and fitting of round conductors in group relation as tape-covered harness means previously used.

Each of the flattened conductors can be substantially uniformly covered by an insulating material which is thermoplastic to permit continuous extrusion thereof around the flattened conductors as well as to permit air-welding thereof into a* build up of free and more parallel conductors in accordance with a disclosure of U.S. Ser. No. 141,519, filed Sept. 28, 1961, now Patent 3,226,278, concerningrProcess and System of Manufacture, thereof. It is noted that the insulation coverings can be made ofa thermoplastic insulating material so as to permit parallel joining of flattened or rolled conductors in accordance with a disclosure of U.S. Ser. No. 141,519, filed Sept. 28, 1961, now Patent 3,226,278, concerning a Process and System of Manufacture. Thus, the flattened conductors are separately insulated though the insulating cover becomes a substantially flat unitary mass heat sealed together along adjacent edges of the individual insulation of the flattened conductors.

FIGURE 1 illustrates a flat conductor harness means generally indicated by numeral and including at least three parallel metal conductors 181, 182 and 183 provided with an insulating covering 184 separable longitudinally where heat fused together in accordance with the disclosure of U.S. Ser. No. 141,519 (Patent 3,226,- 278). Adjacent to one end the harness means 180 can have three window-like cutouts confined. to the conductors 181, 182 and 183 per se and the one conductor such as 181 can have an end thereof projecting axially beyond the limit of the ends of conductors 182 and 183 for polarizing purposes. An opposite end of the flat conductor 181 can be fitted with a male terminal means gener-ally indicated by numeral 185 including a prong-like arcuate pin end 186 as well as a shelf-like conductor engaging end 187 with a step-like recess 188 to receive the insulated flat conductor 181 engageable by a pair of side wings 189 bendable toward each other and into direct engagement with the fiat conductor 181 so as' to establish electrical connection thereto. This male-pin terminal means 185 can be used, for example, as a rear radio speaker terminal connection utilizing the flat or ribbonlike harness means 180 to fit between a rear body panel and a seat or upholstery portion of a motor vehicle. Generally such rear radio speakers are mounted along a shelf behind the upper portion of the rear seat and such flattened harness means 180 can provide a neat and .narrow supply of power to the radio speaker without "3 '3 having any rounded conductors or harness means hanging into a space behind the rear seat and below such a storage shelf.

FIGURE 1 further shows a clip-like retainer or clamping means generally indicated by numeral 190 fitted to the flat harness means 180 and including a generally keystoneshaped main body 191 of insulating material provided with a transverse lateral projection or flange portion 192 integral therewith and adapted to fit longitudinally between flat conductors 181 and 182 through a slot or elongated opening 193 through the insulating material 184 of the flat harness means 180. In certain instances it is possible to have heat fusion of insulating material of the projection or flange 192 into a weld-like juncture 192W of fused plastic material of the projection or flange 192 and insulation 184 of the flat harness means 180. Such a weld or fusion is represented in the view of FIGURE 1.

In FIGURE 2 a slight modification of the attachment of the clamp means 190 is provided in that the flange 192 can be fitted through the elongated slot or opening 193 between the parallel conductors such as 181-182 or 182- 183 and a separable clip retainer portion 194 also of flattened insulating material can be fitted through a passage 195 of the flange or projection portion 192. The main body portion 191 of the clip-like retainer means 190 can be seen in further detail in views of FIGURES 3 and 5 while a plan view of the separable clip retainer portion 194 is provided in FIGURE 4. The clip retainer portion is generally U-shaped in configuration and includes a pair of barbed arms 196 adapted to fit through the passage 195 of the main portion 191 while a pair of extended ends 197 of the secondary and separable clip retainer portion can straddle the flange 192 in locations laterally outside of the passage 195 through the flange or projection portion 192. The primary or main body portion 191 of the cliplike retainer means 190 can include a hole or mounting aperture 198 such that the flat harness means 180 having a flat retainer means 190 secured hereto can be mounted directly to an apertured mounting panel such as a fire wall and the like of a motor vehicle body. Suitable rivet means or nuts and bolts could be used to fit through the aperture or hole 198 for mounting of the clamp-like retainer means carried by the flat harness means 180.

The flat conductors 182 and 183 of the flat wiring harness means 180 can provide electrical connection for front and rear doorjamb switches, for example, of a type illustrated in views of FIGURES 22, 23, 24 and 25 of the copending parent application S.N. 141,483, Baer et al., filed Sept. 28, 1961 (patent 3,226,668), as well as in a copending application S.N. 315,081, Baer et al., filed Oct. 9, 1963, as a continuation-in-part thereof and both belonging to the assignee of the present invention. It is to be noted that the flat harness means 180 can have two, three and more conductors parallel to each other for supply of power to several doorjamb switching devices and the like and that clamp-like retainer means 190 can hold the plurality of parallel conductors in predetermined locations to permit severed ends separable from the flat harness means 180 to be directed to switching devices and the like. The slot-like openings extending longitudinally between pairs of conductors for receiving the flange 192 of the flat clamp-like retainer means main body 191 can be fitted to various harnesses regardless of the number of parallel conductors carried by such harness means since it is necessary only for a slot-like hole to be cut or punched in the flat rectangular-shaped cable harness means such as 180 followed by insertion of the neck-like flange portion 192 of the retainer means through the hole subject to heat fusion or supplemental retainer clip fastening thereof to hold the clamp means in place. The subject clamping means can eliminate costly dies for manufacture and molding of differing sizes of clamps that would be needed to retain rounded harness means to vehicle panel mountings as presently used. It is to be noted that for establishment of electrical connection to the switching device there is no need for additional terminal means directly on the insulated cable since the flattened and severed end of the cable provides one-half of the connection by the conductor itself. The switching device is completely revamped in structure to accommodate flat conductors with no intermediate terminal means per se required to be attached to the severed conductor end. In addition to advantages of saving cost of terminal means there is a saving in space particularly important and noticeable for other door switches such as window-lift control switching means that can be made considerably thinner in cross section for use in thinner doors.

It is to be noted that differing cross sectional sizes of conductors flattened and insulated in accordance with the present invention can be provided for the purpose of carrying various electrical current loads. It is possible also to provide insulation of differing colors around individual though parallel flat strip-like conductors adapted to be joined to each other and adapted to be interconnected with various electrical devices and switching means in proper relationship with each other.

While'the embodiments of the present invention herein disclosed constitute preferred forms, it is to be understood that other forms might be adopted.

What is claimed is as follows:

1. On a flattened wiring harness means having at least a pair of flat conductors each covered with eorresponding insulation material in juncture along contiguous edging except for predetermined opening therebetween, the combination therewith which comprises a clamp-like retainer means including a substantially flat body portion for panel mounting and transverse flange means carried thereby, said flange means having a passage therethrough which is located remote from said body portion upon insertion of said flange means through the opening, and locking arm means complementary to the passage through said flange means that maintains assembly of said clamp-like retainer means to the flattened wiring harness means.

2. On a flattened wiring harness means having at least a pair of flat conductors each covered with corresponding insulation material in juncture along contiguous edging except for predetermined opening therebetween, the combination therewith which comprises a retainer means including a tab-like body portion complementary to one side of the wiring harness means and having a transverse flange portion carried thereby, said flange portion having a configuration that complements the opening through the insulation material in heat fusion juncture therewith.

3. On a flattened wiring harness means having at least a pair of flat conductors each covered with a corresponding insulation material in juncture along contiguous edging except for predetermined opening therebetween the combination therewith which comprises a retainer means exclusively of insulating material including a tablike body portion complementary to one side of the flattened Wiring harness means, said body portion having a mounting aperture therethrough laterally to one side'of the flattened Wiring harness means, and a transverse flange portion of insulating material integral with said body portion in a path that coincides with the opening in the flattened wiring harness means, said transverse flange portion of insulating material having installation through the opening terminated by heat fusion of insulation and insulating materials on a side of the flattened wiring harness means in a location remote from that engaged by said body portion.

4. On a flattened wiring harness means having at least a pair of flat conductors each covered with a corresponding insulation material in juncture along contiguous edging except for predetermined opening therebetween, the combination therewith which comprises a retainer means including a tab-like body portion complementary to one side of the flattened wiring harness, said body portion having a mounting aperture therethrough late-rally to one side of the flattened Wiring harness means, a transverse flange portion on said body portion and having an elongated passage therethrough which is located remote from said body portion upon insertion of said flange portion through the opening of the flattened harness means, and a separable clip retainer portion generally U- shaped in configuration including a pair of barbed arms which fit through the passage of said flange portion on said body portion as Well as including a pair of extended ends shorter than said barbed arms also complementary to said flange portion in a location remote from each other.

6 References Cited UNITED STATES PATENTS OTHER REFERENCES Pohl, German printed application No. 1,112,153 pub- 10 lished Aug. 3, 1961.

LARAMIE E. ASKIN, Primary Examiner. J. F. RUGGIERO', Assistant Examiner; 

1. ON A FLATTENED WIRING HARNESS MEANS HAVING AT LEAST A PAIR OF FLAT CONDUCTORS EACH COVERED WITH CORRESPONDING INSULATION MATERIAL IN JUNCTURE ALONG CONTIGUOUS EDGING EXCEPT FOR PREDETERMINED OPENING THEREBETWEEN, THE COMBINATION THEREWITH WHICH COMPRISES A CLAMP-LIKE RETAINER MEANS INCLUDING A SUBSTANTIALLY FLAT BODY PORTION FOR PANEL MOUNTING AND TRANSVERSE FLANGE MEANS CARRIED THEREBY, SAID FLANGE MEANS HAVING A PASSAGE THERETHROUGH WHICH IS LOCATED REMOTE FROM SAID BODY PORTION UPON INSERTION OF SAID FLANGE MEANS THROUGH THE OPENING, AND LOCKING ARM MEANS COMPLEMENTARY TO THE PASSAGE THROUGH SAID FLANGE MEANS THAT MAINTAINS ASSEMBLY OF SAID CLAMP-LIKE RETAINER MEANS TO THE FLATTENED WIRING HARNESS MEANS. 